Cushioning surgical pad



Sept. 20, 1960 w. M. scHoLl. 2,953,130

CUSHIONING SURGICAL PAD Filed sep't. 18, 195e 2 sheets-sheet 1 Sept. 20, 1960 w. M. scHoLL 2,953,130

CUSHIONING SURGICAL PAD Filed Sept. 18, 1956 2 Sheets-Sheet 2 Ilm Eff@

CUSHIONING SURGICAL PAD William M. Scholl, 211-213 W. Schiller St., Chicago, Ill.

Filed Sept. 18, 1956, Ser. No. 610,596

9 Claims. (Cl. 12S-153) This invention relates to improvements in a cushioning surgical pad, and more particularly to a cushioning device of the type attachable to the body of a user for many and various purposes, the invention being highly desirable for the manufacture of surgical pads, bandages, and the like, and the invention may take any desired form such for example as blister and furuncle shields, corn, callous, bunion, hammer-toe pads and the like, and many other and various types of pads, bandages, dressings, etc. for the alleviation of addictions or the prevention of irritation, as will be apparent to one skilled in the art.

Protective devices of the character of the instant invcntion, particularly those Idesigned for cushioning certain areas of the body, or eliminating pressure or frictional irritation from certain areas, have been made in many styles and forms in .the past. These formerly known devices, however, while in some cases possessing several desiderata, did not in any instance of which I am aware possess most or all of the desiderata in a device of this character. Briefly, these formerly known devices did not possess certain advantages, inter alia, ncluding bending without wrinkling, elimination of abrupt edges, ability to transfer pressure gradually away from a certain area, the effective holding of medicament or exudation and maintaining the same from contacting apparel, adequate long life, presentation of a smooth outer surface over which apparel may freely glide, being inherently fungus resistant, etc. Further, in most cases, manufacture of devices of the character heretofore known required at least one hand operation, particularly in the placing of the devices upon a suitable facing or card, or otherwise mounting the same for adequate packaging for the retail trade.

With the foregoing in mind, it is an important object of the instant invention to provide a cushioning device for attachment to the human body which, in an individual device, possesses all the above mentioned advantages.

Another object of the instant invention is the provision of a cushioning device for attachment to the body of a user which device may consist of thermoplastic laminations heat sealed together at the bounding edge.

A further object of the invention resides in the provision of a cushioning device of the character set forth herein which may comprise thermoplastic laminations heat sealed at the bounding edge in such a manner that the upper lamination has a downwardly curvate margin which effectively encloses the edges of the laminations therebeneath.

While some of the more salient features, characteristics and advantages of the instant invention have been above pointed out, others will become apparent from the following disclosures, taken in conjunction fwith the accompanying drawings, in which:

Figure l is a fragmentary plan View, with parts broken away and parts shown folded back, illustrating the first steps in the process of making the instant invention;

Figure 2 is a greatly exaggerated fragmentary vertitates Patent O ICC cal sectional view taken substantially as indicated by the line II-II of Figure 1, looking in the direction of the arrows;

Figure 3 is a fragmentary plan view illustrating further steps in the construction of the invention;

Figure 4 is a greatly enlarged fragmentary vertical sectional View taken Substantially as indicated by the line iV-IV of Figure 3;

Figure 5 is a plan view illustrating the completion of performance of the method here involved; and

Figure 6 is a greatly enlarged transverse vertical sectional view taken substantially as indicated by the line VI-VI of Figure 5.

As shown on the drawings:

As stated above, the instant invention may be produced in substantially any size and shape desired. The same process may be followed in the manufacture of corn pads of various types and sizes, bunion pads, callous pads, and the like, vaccination and furuncle shields, various shapes of dressings or bandages for alleviating pressure from or friction by articles of apparel on alicted or injured areas, and in the form of devices designed to hold medicament in a particular region or confine exudation from an affliction, without danger of soiling the apparel of the user. Many other and various uses will be apparent to those skilled in the art.

By way of example, and not by way of limitation, I have selected for illustrative purposes an oval shaped pad of the character that might be utilized for alleviating pressure from a callous or the like, as a vaccination or furuncle shield, as a pad for holding medicament over or conning exudation from an abrasion, open sore, or the like, and in many other ways.

For lpurposes of clarity, the instant invention will be described by way of its method of manufacture.

First, a sheet 1 of facing material is placed on any suitable surface such as that of a table or the like. This facing material may be a relatively tough impregnated paper having a release coating so that an article carrying -a pressure sensitive adhesive surface may be readily removed therefrom without delamination of the adhesive and the article, and other satisfactory materials include parchmentized paper, a thermoplastic film, or a sheet of suitable material having a thermoplastic film or coating thereon. In the event a thermoplastic material is used, however, it is preferably a material of -a character not subject to heat sealing, at least at a temperature to which the other laminations to be later described are responsive. In short, the sheet 1 may be of any suitable material capable of functioning as a ternporary protective covering for a pressure sensitive adhesive surface, the facing material being removed from the adhesive surface and discarded when the device is put to use.

Upon the sheet 1 is laid a sheet or lamination 2 which is ultimately a portion of the finished article. This lamination 2 is preferably a thermoplastic lm and, as seen in Figure l, carries a pressure sensitive adhesive 3 on its under surface by which the finished device is ultimately applied to the body of the user. The sheet 2 is pressed upon the facing sheet 1, and the opposite face of 'the sheet 2 may be ygiven a coating 4 of a thermoplastic cement, such as a vinyl cement.

Secured to the thermoplastic film 2 by way of the cement 4 is another lamination or sheet 5 which is preferably a thermoplastic foam. This lamination, of course, functions as the cushioning element o-f the complete structure 'and as'seen clearly as in Figure 2 is preferably considerably thicker than the film or sheet 2. It will be understood that the cement 4 bonds the laminations 2 and 5 to each other in face to face relationship.

It may be mentioned at this point, that all of the havel theY sheet 1 of Yfacing material of slightly greater area than the laminationsY thereupon so as to facilitate removal of waste.

A number of thermoplastic foams and thermoplastic n sheets or iilm material are suitable for. the purpose of the instant invention, but by way of specific example and not by Way of limitation, I may mention that a very satisfactory substance is vinyl foam made from a liquid composition generically known as a plastisol. f The plastisol is expanded preferably by the use of an inert gas, and Vthen cured in the Yexpanded condition to provide a light Weight structural material that is highly flexible, resilient, and possesses inter-communicating cells. The plastisol may satisfactorily be a dispersion or suspension of polyvinyl chloride'resin, or a copolymer in one or more plasticizers selected from a large number of high boiling esters, for example, such as dioctyl phthalate, dioctyl adipate, dicapryl phthalate, etc.

The sheet of thermoplastic film 2 may yalso be vinyl Viilm having the same chemical constituency as the foam,

but made under a process devoid of expansion, beingV rolled on a calender or the like into a finished and considerable denser sheet. Either of the Sheets may be made in Vsubstantially any desired color. Further, it should be mentioned that the foam lamination 5 has the f advantages of light weight, softness, the fact that it conforms and molds to high points or contours of the body, does not mat of flatten, gives a continuous and proper balanced cushioning effect, possesses excellent resiliency, and does not press back against whatever presses upon it. This latter advantage is useful when the cushioning device is worn underneath the foot, because as disting'uished from the instantaneous recovery of foamlatex, the plastic foam has a lag in its recovery and does not exert back pressure, although it readily absorbs the shock of pressure of the foot. It should also be noted that the device as a whole possesses exceedingly long life, and is hygenic, effectively resisting fungus and bacteria.

After the laminations 2 and 5 are Aassembled upon facing sheet 1 as above described, a seriesV of spaced apertures 6 may be punched through the entire assembly, these apertures being of a contour in keeping with the As the sheet is passed through the machine, the laminations 2, 5 vand 7 are electronically heat sealed together, and in the illustrated instance this is accomplished along a seam indicated at 8 which defines the contour of the finished article. At the same time, the pressure is sufiicient to substantially sever each article from the superposed laminations so .that it is a simple expedient to withdraw the waste material leaving just the iinished pads themselves remaining upon the facing sheet 1 as seen in Figures 5 and 6. The facing sheet is unaffected by the heat sealing process. Y e

Following the removal of the waste Aafter the heat sealing operations, the facing sheet 1 may be severed as indicated by the dotted lines 9 in VFigure 5 in the separate pieces, each carrying one of the iinished pads.

Y As shown, the severed pieces of facing strip are preffunction of the particular device being made. For ex-` ample, in some instances, round apertures may be preferred, and in other instances oval apertures or those of some other contour depending entirely upon the circumstances or ultimate use of the device.

Following the punching of the apertures 6, a cover i sheet or lamination 7 is disposed over the foam lamination 5 as seen in Figures 3 and 4. The lamination 7 is also a thermoplastic material, and may be of the same chemical constituency as the lamination 2. However, in many instances it is desirable to have the `top lamination substantially transparent and that is the way it is illustrated in the drawings. This top lamination 7 covers not only the foam lamination 5 but also extends over the apertures 6. The top lamination 7 is 'notsevcured to the foam lamination therebeneath in face-toduring'the heat sealing and severing of the cushioning devices. Y The Vassembly so far describedris then placedfin an electronic heat sealing machine, aV bufferV such as a Yphenolic condensation product or other dielectric medium,

being used if desired. Such a machine is,` of course,

` equipped with'a pair `of electrodes which may bepbrought together in the form of a press, and at least one of Vthese 'e1ectrodefdies, usuallythe upper, is shaped in keeping with the desired contour of thefmished article.

erably of greater area than the pads, to facilitate removal of the pad from the strip at the time the pad is put to use. Likewise-the facing strip may be severed as indicated by the dotted line 10 so that two or more pads remain upon a single piece of facing sheet. VWith this process, there is no need for any hand operations in placing the finished devices upon a facing member for disposition in a consumer package. 'It is merely necessary to sever the original Vsheet 1 into the desired size Yfor that purpose. That, of course, may be done mechanically and economically.

Now with reference to Figures 4 and 6 particularly, it i will be seen that the finished device embodies a downwardly curvate margin therearound as indicated in genveral by numeral 11. This rounded margin of the appliance permits ready donning of apparel after the device has been placed on the body of the user, without any danger of the apparel catching and tending to rip the device partially loose. Further, such contouring re- Vsults in a comfortable iit when the device is placed beneath a tight fitting article of apparel such `as a shoe.

All abrupt edges 4have been eliminated and the device eifectively transfers pressureaway from the `ailiicted area which should, of course, be disposed Within the cavity formed by the aperture 6.

It will furtherbe noted that the upper thermoplastic film `lamination 7 presents `a smooth surface 'over which articles of apparel may freely glide. The top lamination 7 also curves downwardly so las to substantially 'completely enclose the edge of the cushion lamination 5, land merge With the' lower lamination 2 although the cushion layer is caught Iat its edge in the heat seal. It is Ytherefore apparent that when the device is attached to the body of a user, exudation from an affliction or medicament placed V'over the affliction within the aperture 6 will be effectively retained and prevented from contacting apparel. Further, where the cover or top lamination 7 is substantially transparent, the condition of the aiiiiction may beviewed through the device with- 4out requiring 4its removal for that purpose. L

Another `distinct advantage is embodied in this invention in that the device may be applied to the body of a -user is la bent or distorted condition without external wrinkling. This is due to the'ffact that the top lamination 7 is not connected or secured to the cushion lamination there-beneath except at the very bounding edge, namely the seam of the heat sealing operation. Thus, when theV device is bent'or distorted relative movement between the 1top lamination andthe cushioning `lamination isV permitted.

It should be noted that under certain conditions of use i-t may be desirable to eliminate either the film Z or the film 7 as the case may be. Also, it should be borne in mind that it is not necessary for the foam layer 5 to be secured to the lm 2 since the heat seal will effectively bond the laminations together.Y Y

From therforegoing, it is apparent that IYhave provided a novel and; highly efiicient cushioning Vdevice for application directly to the human body. The device is long lived, may be -left in useful position =for an indefinite length of time, is substantially waterproof, and exceedingly comfortable to the user. When .the device is made by -the method hereinabove set forth, it obviously may be manufactured extremely economically. I-t Will be understood that modications and variations may be eiected without departing from the scope `of the novel concepts of the present invention,

I claim as my invention:

l. A surgical pad comprising a thermoplastic lm having a pressure sensitive adhesive on its undersurface, a thermoplastic cushion layer secured to the upper surface of said lm, and a top thermoplastic lm laid over said cushion layer, and said lms being secured together by `a heat seal seam around Ithe bounding edge of said pad with said top lm in 'continuous abutting relation with said cushion layer and enclosing said cushion layer.

2. In a self-adhering pad and the like, a plastic film carrying pressure sensitive adhesive -on its outer face, a plastic cushion layer overlying the inner face of said lm, and said layer and film being connected together at the bounding edge of the pad by a heat seal seam, said cushion layer having a curvate margin terminating in a tine edge at the heat seal seam. v

3. In a surgical pad and the like, a relatively thick layer of vinyl plastic cushioning material, and a vinyl plastic lm overlying said layer in continuously abutting, free relationship and connected to the bounding edge thereof by a heat seal seam.

4. In a surgical pad and the like, a :relatively thick layer of vinyl plastic cushioning material, and a plastic film overlying said layer in continuously abutting, free relationship and connected to the bounding edge only thereof by a heat seal seam, and pressure sensitive adhesive means carried by the outer -face of said layer.

5. In a surgical pad and the like, a relatively thick layer of plastic cushioning material, and a plastic lm overlying -said layer in continuously abutting, free relationship and connected to the bounding edge thereof by a heat seal seam, said layer having an intermedia-te opening therethrough covered by said film, and said layer and said lm being tree yfrom each other except for the junction at the heat seal.

6. In a cushioning device for attachment to the body of a user, a laminated structure comprising a layer of plastic cushioning material, and a sheet of plastic material overlying one side of said layer in continuously abutting, free relationship and connected thereto at the bounding edges of the layer and sheet by a heat seal seam, said layer carrying an adhesive on the opposite :side thereof, and said sheet and layer being free from each other except for the heat seal.

7. In a cushioning device for attachment to the body of fa user, a `laminated structure comprising a relatively thick and initially at layer of plastic cushioning material, a thin sheet of plastic material overlying one side of said layer in continuously abutting, free relationship therewith, said sheet and layer being connected together at their bounding edges by a heat seal seam With said sheet curving downwardly to enclose the relatively thick edge of said layer which is held compressed by said heat seal seam.

8. In a cushioning device for attachment to the body of `a user, a laminated structure comprising a Irelatively thick and initially ilat layer of plastic cushioning material, a thin sheet of plastic material overlying one side of said layer in continuously abuttin-g, free relation therewith, said sheet yand llayer having a downwardly curvate margin therearound `and being vconnected together at their bounding edges by a heat seal seam whereby the sheet encloses the relatively thick edge of the layer and holds the curvate margin of the layer.

9. A cushioning device for attachment to the body of a user, comprising a vinyl lm carrying adhesive on one face thereof, a layer of vinyl foam overlying the other face of said film, and a 'top vinyl lm overlying said lfoam layer in continuously abutting, 4free relationship therewith, lsaid layer and said lms being connected together at the bounding edges thereof by a heat seal seam much less in thickness than the initial thickness of the foam layer alone.

References Cited in the tile of this patent UNITED STATES PATENTS 

1. A SURGICAL PAD COMPRISING A THERMOPLASTIC FILM HAVING A PRESSURE SENSITIVE ADHESIVE ON ITS UNDERSURFACE, A THERMOPLASTIC CUSHION LAYER SECURED TO THE UPPER SURFACE OF SAID FILM, AND A TOP THERMOPLASTIC FILM LAID OVER SAID CUSHION LAYER, AND SAID FILMS BEING SECURED TOGETHER BY A HEAT SEAL SEAM AROUND THE BOUNDING EDGE OF SAID PAD WITH SAID TO FILM IN CONDITION ABUTTING RELATION WITH SAID CUSHION LAYER AND ENCLOSING SAID CUSHION LAYER. 